Insert for integration into trim layer and providing conditioning

ABSTRACT

An insert comprising: (a) a cover layer; (b) a spacer layer located below the cover layer; (c) a connection material that is adapted to extend between and connect the cover layer to a trim layer so that the insert is fixed to the trim layer.

FIELD

The present teachings relate generally an insert that provides climatecontrol, and more specifically an insert that is integrated into a trimlayer so that one or more blowers provide conditioning to a vehicleseat.

BACKGROUND

For many years, industry has been concerned with designing improvedconditioning systems for articles of manufacture such as seats, steeringwheels, automotive vehicles, or other transportation vehicles. Examplesof such conditioning systems are disclosed in U.S. Pat. Nos. 5,176,424;6,626,488; 6,869,140; 7,452,028; and 7,478,869; and U.S. PatentApplication Publication Nos. 2015/0329027 and 2017/0136926 all of whichare expressly incorporated herein by reference for all purposes. Manysystems include a conditioner that is located on a top of a seat with ablower that is located on a bottom of the seat such that air is movedfrom a remote location to the insert to distribute the air. Some systemsinclude an extended tail that extends from a location on top of the seatto a location behind or under the seat where a blower is located. Thesesystems include a blower that is connected to the seat frame and thetail connects the inset to the blower. The conditioner is placed on theseat and may be held in place by a recess in the seat or the trim layerbeing attached over the conditioner and the seat.

What is needed is an insert that is configured to be integrated into thetrim layer of a vehicle seat. What is needed is an insert and trim layerthat are applied simultaneously. It would be desirable to have an insertthat is connected to the trim layer so that fastening of the trim layerfastens the insert on the vehicle seat. What is needed is an insert thatconnects to the trim layer and has a profile that cannot be felt by anoccupant of the vehicle seat. It would be desirable to have an insertthat is self-contained and internally includes a heater, a spacer layer,or both.

SUMMARY

The present teachings include: a conditioning system comprising: (a) ablower; (b) an insert in communication with the blower, the insertincluding: (i) a cover layer, (ii) a heater located under the coverlayer, and (iii) a spacer located under the heater; wherein the insertis integrally connected to a trim layer of a vehicle seat so that thetrim layer and the insert form a unitary piece.

The present teachings provide an insert that is configured to beintegrated into the trim layer of a vehicle seat. The present teachingsprovide an insert and trim layer that are applied simultaneously. Thepresent teachings provide an insert that is connected to the trim layerso that fastening of the trim layer fastens the insert on the vehicleseat. The present teachings provide an insert that connects to the trimlayer and has a profile that cannot be felt by an occupant of thevehicle seat. The present teachings provide an insert that isself-contained and internally includes a heater, a spacer layer, orboth.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of an insert connected to a trim layer;

FIG. 1B is a cross-sectional view of the conditioning system of FIG. 1Aalong line 1B-1B with the conditioning system including an insert havingmultiple spacer layers integrated into a trim layer;

FIG. 1C is a cross-sectional view of the conditioning system of FIG. 1Aalong lines 1C-1C;

FIG. 2 illustrates a cross-sectional view of an insert including onespacer layer integrated into a trim layer;

FIG. 3 illustrates a cross-sectional view of a trim layer an insertwithout a bottom layer integrated into a seat and connected to a blower;

FIG. 3A is a close-up view of an inlet into the insert and the openingfrom the cushion;

FIG. 4A illustrates an insert with sealed edges integrated into a seatand connected to a blower;

FIG. 4B illustrates an insert that has open edges integrated into a seatand connected to a blower;

FIG. 4C illustrates a top view of a cover layer including connectionmaterial;

FIG. 4D illustrates a top view of a cover layer including connectionmaterial;

FIG. 5A illustrates a top view of an insert having a connection regionthat receives a connection device;

FIG. 5B illustrates a top view of an insert having a connection regionwith a plurality of connection holes that receive a connection device;

FIG. 5C illustrates a trim layer and insert located within a seat and influid communication with a blower that is connected to the seat via ashield; and

FIG. 5D illustrates a trim layer and insert located within a seat and influid communication with a blower that is connected to the seat via afoam connection.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Those skilled in the art may adapt andapply the invention in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present invention as set forth are not intended as beingexhaustive or limiting of the teachings. The scope of the teachingsshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes. Other combinations are also possible as willbe gleaned from the following claims, which are also hereby incorporatedby reference into this written description.

The present teachings are predicated upon providing an improvedconditioning system suitable for integration into a vehicle. Forexample, the conditioning system may be integrated into or attached tocarriers (e.g., members, structures, panels, floors, walls, or the like)of various articles of manufacture such as buildings, furniture,transportation vehicles, (e.g., boats, trains, airplanes, motorcycles,all terrain vehicles, busses, snowmobiles, or otherwise) or the like.Alternatively, the conditioning system may be integrated into orattached to various components of transportation vehicles such as seats,benches, panels, footwells, floor mats, or other components. Preferably,the conditioning system is integrated into a vehicle seat. Morepreferably, the conditioning system is integrated into a trim layer andthe trim layer connects the insert to the vehicle seat.

The conditioning system is particularly suitable for integration into aseat of an automotive vehicle. More particularly, the conditioningsystem is suitable for integration with the seat portion with or withoutbolsters, back portion with or without bolsters, head rest portion, or acombination thereof. The conditioning system may be located between twolayers of the seat. The conditioning system may be part of a trim layer(e.g. cloth, leather, synthetic leather, or the like). Preferably, theinsert of the conditioning system is connected to an becomes part of thetrim layer. For example, during installation of the trim layer theinsert is installed without a need for separate steps of installing theinsert and the trim layer. The insert may be located proximate to acushion or backrest (e.g. a foam support for the user). The insert mayinclude all or a portion above the cushion, below the cushion, or both.Preferably, the insert is substantially entirely located above thecushion. The insert may be located within a recess in a cushion. Aportion of the conditioning system (e.g., insert) may be located abovethe cushion and a portion of the conditioning system (e.g., blower,shield, connection insert, or a combination thereof) may be locatedbelow the cushion. The present conditioning system is particularlyattractive for use in combination with a conditioned seat (e.g. aventilated, actively cooled (such as by use of a thermoelectric deviceor module), or actively heated seat). The conditioning system may beintegrated with the seat cover by way of sewing, gluing, other methods,a friction fit, being located between two static layers, or acombination thereof. The conditioning system may include one or moreblowers and one or more inserts (i.e., ventilated trim bags); one ormore heaters, one or more thermoelectric devices, or a combinationthereof.

The conditioning system may include an active heating element (i.e.,heater), an active cooling element, cooling through convection, or acombination thereof. The active heating element may be a resistiveheating element. The heating element may be a PTC heater, a resistivewire, or both. The heating element may generate heat upon currentflowing through the heating element. The heater may be located on acover layer of the insert. Preferably, the heater is located under acover layer of the insert. The heater may be located between a spacerlayer and a cover layer. The heater may be an integral part of theinsert. The heater may be connected to the cover layer, the insert, orboth so that the heater may be free of movement relative to the coverlayer, the insert, the trim layer, the cushion, or a combinationthereof. The heater may be connected to the spacer, the cover layer orboth by one or more connection materials. The heater may be locatedbetween two connection materials. The heater may be embedded in aconnection material. The heater may be connected to a rear side of thecover layer by a connection layer that is sewing and a connection layermay extend over a rear side of the heater and a forward layer of thespacer layer. The heater may be a single resistive wire that is appliedto the cover layer, the spacer layer or both in a pattern. Theconditioning system may be free of a resistive heater. For example, athermoelectric device may be used to produce heat. The conditioningsystem may include one or more air movers that assist in distributingheat, cooling, or both.

A conditioned seat may include one or more air movers (air movers andblowers are used interchangeably herein). The one or more blowers maymove air through one or more inserts that are located within or overlaythe backrest cushion, seat cushion, or both. The one or more inserts maydistribute air from the blowers. The one or more blowers may be an axialfan, a radial fan, or both. Preferably, the one or more blowers are aradial fan. The one or more blowers may include a Thermoelectric Device(TED). The TED may heat air as it enters the blowers or as it leaves theblowers. The TED may cool air as the air enters the blowers or as theair leaves the blowers. The one or more blowers may include a heatingdevice, a cooling device, or both (i.e. a thermoelectric device (TED)).The TED may be used to heat air and/or cool air that is blown onto theuser. The blowers and TED may be placed in the seat or on the seat inmany different configurations or in communication with a vehicle seatinsert. For example, the TED and/or air mover may be used in any manneror any configuration with an insert described in any of U.S. Pat. Nos.RE38,128; 4,923,248; 6,629,724; 6,676,207; 6,857,697; 6,869,139;6,869,140; 6,976,734; 7,083,227; 7,213,876; 7,338,117; 7,356,912;7,475,938; 7,506,938; and 7,587,901 or U.S. Patent ApplicationPublication No. 2009-0218855 the teachings of which are expresslyincorporated by reference herein for all purposes. The TED and heatermay both produce heat at the same time; however, it is contemplated thatthe TED or heater may be used separately. The heater may be used toproduce heat in an active heating system in place of a TED. The heater,preferably, may not be used when the TED is used to cool the user. Theair mover and TED may be used in conjunction with an insert disclosedherein so that air may be directed evenly and consistently to the user.The air may be blown through the insert, a heater, perforations in theseat cover (e.g. trim layer), holes or perforations in a cushion, or acombination thereof. Some examples air permeable seats and heatingdevice are U.S. Pat. Nos. 6,064,037 and 6,869,140 both of which areincorporated by reference herein for all purposes. The TED may produceheat and the blower may blow the hot air while the heatercontemporaneously heats the seat; thereby, providing both conductionheating and convection heating. One or more blowers may move air acrossthe TED so that conditioned air is moved into contact with an occupant.

The blower functions to push air, pull air, or both. The blower may bemovable with the cushion, the insert, or both as an occupant sits on thecushion or leaves the cushion. The blower may be an axial fan.Preferably, the blower may be a radial fan. The blower may include oneor more impellers that move air through the blower, the blower housing,the insert, or a combination thereof. The blower includes an inlet andan outlet. The inlet may be on the bottom side or the top side.Preferably, the inlet is in the bottom side of the blower. The blowermay be connected to the cushion and free of direct connection with theinsert. The blower may be connected via a shield, a connection insert, afoam connection, or a combination thereof. The blower may be located ona b-side of a vehicle seat, a cushion, or both. The inlet or the outletof the blower may be connected to the insert via an attachment device.

The one or more attachment devices may function to connect a blower tothe insert, cushion, or both. The one or more attachment devices mayconnect one or more blowers to a cushion, a frame of a seat, an insert,or a combination thereof. The blower may be suspended below theattachment device. The blower may be connected to the insert by a tail.The tail may extend from a side of the insert around a portion of thecushion so that the blower may be located distal from the insert. Theone or more attachment devices may reside entirely below a cushion. Theone or more attachment devices may reside entirely within a cushion. Theone or more attachment devices may be located partially below a cushionand partially extend into a cushion. The one or more attachment devicesmay be located entirely within a through hole, channel, or both in thecushion. The one or more attachment devices may be rigid. The one ormore attachment devices may be made of an air impermeable material. Theone or more attachment devices may be pliable. The one or moreattachment devices may elastically deform. The one or more attachmentdevices may move with the cushion, the insert, or both so that theinsert is not felt by an occupant. The one or more attachment devicesmay mimic the stiffness of the cushion, the insert, or both so that theblower moves with the cushion, the insert, or both. The one or moreattachment devices may be made of or include a polymer, plastic, aclosed cell material, a plastic film, a polyester film, metal, or acombination thereof. The one or more attachment devices may be airimpermeable. The one or more attachment devices may be flexible. The oneor attachment devices may be a shield, a connection insert, a foamconnection, or a combination thereof.

The one or more shields function to prevent air from moving out of abottom side of a cushion. The one or more shields may cover one or morethrough holes within the cushion. The one or more shields may cover arear surface of the cushion and prevent fluid from exiting the cushionvia recesses, pores in the cushion, or both. The one or more shields maysubstantially seal a rear side of a cushion (i.e., the shield preventsair from being diverted from the air move to a location other than thethrough holes). The one or more shields may connect to the cushion andcreate a barrier on the rear side of the cushion. The one or moreshields may connect a blower to the cushion. The one or more shields maydivert air from the air mover to the one or more through holes withinthe cushion. The one or more shields may form a seal along edges so thatthe shield proximate to the cushion so that the one or more shieldsprevent fluid leakage. The one or more shields may be air impermeable.The one or more shields may be a rigid material. The one or more shieldsmay include an elastomer or have some elastomeric characteristics. Theone or more shields may be made of polyethylene (high or low density),polypropylene, polyvinyl chloride, polystyrene, nylon, thermoplasticpolyurethanes, polyamide, or a combination thereof. The one or moreshields may be used in lieu of or in addition to a connection insert, afoam connection, or both.

The one or more connection inserts function to connect a blower to theinsert. The one or more connection inserts may extend from a back side(B-side) of the cushion to a top side (A-side) of the cushion or aportion of the distance therebetween. The one or more connection insertsmay suspend the blower from the insert, the cushion, or both. The one ormore connection inserts may be expandable and contractible. The one ormore connection inserts may have an accordion shape. The one or moreconnection inserts may be elastomeric or include an elastomer. The oneor more connection inserts may be air impermeable. The one or moreconnection inserts may be made of any of the materials discussed hereinfor the one or more shields. The one or more connection inserts maycreate a conduit. The one or more connection inserts may not support ablower and the blower may be supported by the cushion, the frame, orboth. The one or more connection inserts may connect to a rear layer ofthe insert. The one or more connection inserts may form a fluid conduitthrough each of the one or more through holes in the cushion to ablower. The one or more connection inserts may connect to a shield, afoam connection, or both.

The one or more foam connections may function to provide air from theblower to the through holes within the cushion. The one or more foamconnections may function to support the blower. The one or more foamconnections may function to provide air to a through hole within acushion and prevent the air from exiting from the through holes. The oneor more foam connections may extend from an a-side to a b-side of acushion or a distance therebetween. The one or more foam connections maybe hollow. The one or more connection inserts may be compressible andinserted into the cushion and then expand to connect to the cushion. Theone or more foam connections may be air impermeable. The one or morefoam connections may have a trunk that connects to the blower. The trunkmay be a main body portion that is in communication with the blower. Thetrunk may be located external of a cushion. The trunk may fluidlyconnect the blower to one or more branches. The one or more branches mayextend fully or partially into the cushion. The one or more branches maybe the same size as the trunk. The one or more branched may be smallerthan the trunk. The one or more foam connections may have one or more ortwo or more branches that extend from the trunk to distribute air. Theone or more foam connections may have a plurality of branches. The oneor more branches may extend at least partially into a through holewithin the cushion. The one or more branches may turn and extend at anangle relative to the trunk. For example, the trunk may extend parallelto a bottom of the seat and the branches may extend perpendicular to thetrunk. One or more foam connections may be made of an open cell materialand may be coated or wrapped with a material that prevents fluid fromexiting the foam connections. The one or more foam connections may be aclosed cell foam. The One or more foam connections may connect to thecushion, a frame, or both.

The cushion may function to support an occupant, a blower, or both. Oneor more cushions of the seat may include ventilation, active cooling,active heating, or a combination thereof. The seat may include one ormore air movers (i.e. blower) in fluid connection to the one or cushionsso that air may be blown onto the user or so that air may be pulled awayfrom the user. The cushion may be connected to or part of a conditioningsystem. The one or more cushions may be a foam material that providescushioning to an occupant seated on the cushion. The one or morecushions may include one or more through holes that extend from a bottomof the cushion to a top of the cushion. The cushion may include one ormore connection members that the insert, the trim layer, or bothconnect.

The one or more connection members function to retain the trim layer,the insert, or both on a cushion, in communication with an insert, orboth. The one or more connection members may be connected to thecushion. The one or more connection members may be integrated into thecushion. The one or more connection members may be a rod, hook, or boththat is integrated into the cushion when the cushion is formed. The oneor more connection members may be a metal, plastic, a natural material,a synthetic material, a rope, a chord, or a combination thereof that isintegrated into a foam cushion during manufacture of the cushion. Theconnection members may be sufficiently rigid so that the connectionmembers prevent movement of the trim layer, the insert, or both relativeto the cushion. The one or more connection members may be formed intothe cushion adjacent to one or more through holes. The one or morethrough holes may function to allow fluid to extend from through thecushion. The one or more through holes may prevent fluid from leaking asfluid extends from the blower to the insert. The one or more throughholes may connect to the blower, the insert, the attachment devices, ora combination thereof. The one or more through holes may be round, oval,square, diamond, symmetrical, asymmetrical, or a combination thereof.The one or more through holes may extend between a b-side and an a-sideor a recess of the cushion. The one or more through holes may extend toa top surface, a surface within a recess, or both. The one or morethrough holes may be sufficiently large so that an attachment member mayextend into the through hole. The cushion may have one through hole thatprovides fluid to an insert. The cushion may have a plurality of throughholes. The one or more through holes may form a channel through thecushion.

The channel may function to direct air between two locations. Thechannel may be an internal passageway within a through hole. The channelmay house all or a portion of a blower, an attachment member, or both.The channels may terminate within a recess of the cushion. The one ormore recesses function to receive an insert. The one or more recessesmay prevent movement of the insert relative to the trim layer, thecushion, or both. The one or more recesses may be complementary in shapeto the shape of the insert. The one or more recesses may be square,rectangular, symmetrical, asymmetrical, triangular, trapezoid, or acombination thereof. The one or more recesses may be substantially asame size and shape as the insert. The one or more recesses may preventthe insert from moving. The one or more recesses may form a wall of theinsert. For example, an upper wall of the recess may from a rear layerof the insert so that fluid is directed into the spacer layer. The oneor more recesses may be larger than the insert in one or moredirections. For example, a length of the recess may be larger than theinsert so that some air escapes from the insert or extends around theinsert and is directed towards the occupant. The recess may be largerthan the insert so that a gap is located between a wall of the insertand a wall of the recess. The insert may have one or more steps. Thesteps may receive a seam, a portion of the insert, or both. The one ormore recesses may function to assist the trim layer in preventingmovement of the insert.

The trim layer may function to support the insert, form a layer of theinsert, or both. The trim layer may cover the cushion, the seat, orboth. The trim layer may assist an insert in directing air topredetermined locations. The trim layer may be a fluid permeablematerial and may allow air to flow from the insert to an occupant. Thetrim layer may be made of or include an fluid impermeable material thatincludes holes or perforations that direct air to a predeterminedlocation (e.g., leather, a polymer film layer on a cloth seat). The trimlayer may be cloth, leather, a synthetic material, or a combinationthereof. The trim layer may directly contact an occupant upon anoccupant sitting within a vehicle seat. The trim layer may be connectedto the insert via a connection material.

The connection material may function to integrate the trim layer and theinsert. The connection material may connect the insert to a layer of thetrim layer. The connection material may connect a plurality of layerstogether so that each individual layer is connected to the trim layer.The connection layer may extend along one or more layers. The connectionlayer may extend through one or more layers. The connection layer maychemically adhere one or more layers together, the insert to the trimlayer, or both. The connection layer may mechanically connect one morelayers together, the insert to the trim layer, or both. The connectionlayer may be a liquid adhesive, a dry adhesive, a one part adhesive,gluing, a two-part adhesive, an air permeable adhesive, an airimpermeable adhesive, a peel and stick layer, or a combination thereof.The one or more connection layers may be heat staking, sewing, or both.The connection layer may connect the cover layer to a heater, a heaterto a spacer layer, a cover layer to a spacer layer, a spacer layer to arear layer, a spacer layer to a second spacer, layer, a cover layer to atrim layer, a spacer layer to a cushion, a spacer layer to a recess, ora combination thereof. The connection layer may extend between orthrough the rear layer and the cover layer. The connection layer mayextend between or through the rear layer, the cover, layer, and the trimlayer. For example, the rear layer, the cover, layer, and the trim layermay all be sewn together. The rear layer and the cover layer may beconnected together before both layers are connected to the trim layer.For example, the rear layer and cover layer may be heat steaked togetherand then adhered to the trim layer. The connection layer may includeboth mechanical connectors and chemical connectors. For example, gluingor melting and sewing may be used. The connection layer may be appliedin a pattern to any of the layers of the insert. The connection layermay be located along two opposing edges. The connection layer may extendaround a peripheral edge region. The connection layer may have a windowpattern (e.g., 4 squares in contact). The connection layer may beapplied so that an “X” with no connection layer is formed within theconnection material. The connection layer may be applied around the ventholes. The connection layer may be one or more strips, two or morestrips, three or more strips, or four or more strips. The connectionlayer may be free of being located within a center or a central regionof any of the layers of the insert. The connection layer pattern mayextend around trenches, be free of a location proximate to a trench, orboth. The insert may be directly connected to the trim layer without anyintervening layers or material. The insert and trim layer may extendover one or more occupant sensors.

The conditioning system may be used in conjunction with an occupantsensor. An occupant sensor may be used on any seat in conjunction with aconditioning system. Preferably, an occupant senor may only be used onpassenger seats. The occupant senor may be any type of occupant senorthat senses a passenger in a vehicle seat. The occupant senor may be amembrane sensor, a capacitive sensor, a force sensor, a mass sensor, ora combination thereof. The occupant sensor may be a sensor wire. Theoccupant sensor may be in contact with the insert. Preferably, theoccupant sensor is located on a top of a cushion. The occupant sensormay be located between the trim layer and the insert. The occupantsensor may be connected to the trim layer or integrated into the trimlayer and then insert connected below the occupant sensor. The occupantsensor may be connected to the insert and then both the insert andoccupant sensor connected to the trim layer. The occupant sensor mayhave a mirror shape to the shape of the insert.

The insert may function to receive and distribute air. The insert mayfunction to connect to the trim layer and distribute air to or from anoccupant. The insert may function to maintain an open space when anoccupant is located on the seat, on the insert, or both. The insert mayinclude one or sealed edges (e.g., seams). The insert may include openedges. The insert may include one or more cover layers and one or morerear layers with one or more spacer layer layers extending between theone or more cover layers and the one or more rear layers. The insert maybe one or more layers sandwiched together. The insert may be one or morelayers contained between a cover layer and a rear layer. The cover layermay be directly connected to one or more spacer layers and the one ormore spacer layers may be directly connected to a rear layer. Each ofthe layers may be connected together by one or more connectionmaterials. The insert may be free of a rear layer, a cover layer, orboth. The insert may include one or more holes in the one or more coverlayers, one or more rear layers, or both. The insert may receive airfrom an air mover and distribute the air to predetermined locations. Theinsert may create an open space. The ventilated insert may resistcrushing when an occupant sits in a vehicle seat. For example, theinsert may not completely seal off and air may flow through an entirevolume of the insert. The insert may include cutouts, internal slits,external slits, voids, apertures, carrier configuration, or the like maybe shaped similarly or be aligned with the perforations in the seatcover. The insert may be one portion. The insert may be multiple insertportions.

The insert portions may function to prevent read through, prevent theinsert from extending into a trench, distribute fluid to two or moreregions, control air flow in desired regions, or a combination thereof.The insert portions may be fluidly connected. The insert may be fluidlyseparate. One attachment device may connect to each of the insertportions so that a single blower may move fluid through each of theinsert portions. The insert portions may be mechanically connected. Theinsert portions may include a connection region that extends between afirst insert portion and a second insert portion. The insert may includea plurality of connection regions. The insert may include a plurality ofinsert portions. The insert portions may be separated by one or moreconnection holes. One or more connection devices may extend between theinsert portions and the insert portions so that an occupant in contactwith the insert portions may not feel the connection devices. Forexample, a connection device (e.g., a hog ring) may connect to aconnection region and the insert portions may maintain an occupant abovethe connection device so that an occupant does not feel the connectiondevice, a trench, or both. The two or more insert portions may extendalong one or more trenches. Each of the insert portions may extend alonga trench so that a connection region extends over the trench. The insertportions may be mirror images of each other. The insert portions mayeach include an opening.

The opening may function to fluidly connect the air mover with theinsert, the spacer material, or both. The opening may be in a rear layerof the insert. The opening may permit air to move from the spacer layerto the blower or from the blower to the spacer layer. The opening in therear layer may be larger than the channel, the through hole, or both.The opening may be an absence of material in the rear layer. The rearlayer may function to allow air to enter into the insert and to directair towards exit locations. The rear layer may be permeable. Preferably,the rear layer may be impermeable, include an impermeable coating, orboth. The rear layer may be a porous material. The rear layer may be afilm. The rear layer may be made of a polymeric material. The rear layermay be made of polyester, biaxially oriented polyethylene terephthalate,polyvinyl fluoride, polyethylene, polypropylene, nylon, polyvinylchloride, or a combination thereof. The rear layer and the top layer maybe made of the same material. The rear layer may be one or more layers.Preferably, the rear layer is a single layer. The rear layer may connectto a shield, connection insert, foam connection, connection inserts, ora combination thereof. The rear layer may extend over the cushion toprevent fluid from exiting through the cushion. The rear layer maycreate a fluid barrier between the spacer layer and the cushion. Therear layer may direct fluid from the attachment devices into the insert.The rear layer may connect to the cover layer. The rear layer may befree of contact with the cover layer. The rear layer may extend parallelto the cover layer. The rear layer may be located between the spacerlayer and the cushion. The rear layer may connect to a connector and theconnector may be connected to the blower. The rear layer may beseparated from a cover layer by a spacer layer.

The one or more spacer layers may function to create an open spacebetween the cover layer and the rear layer. The one or more spacerlayers may prevent the rear layer and the cover layer from being movedinto contact. The one or more spacer layers may include one or more ventholes. The spacer layer may be a mesh material. The spacer layer mayresist compression. The spacer layers may be resistant to filer. Thespacer layers may be recyclable. The spacer layer may form a space forair to move through the insert. One example of a preferred material ofthe spacer layer is 3mesh® spacer layer material manufactured by MullerTextile of Wiehl, Germany. The spacer layer may be one or more layers ofmaterial. The spacer layer may include two layers of spacer layer. Whentwo or more spacer layers are present one or both of the spacer layersmay include one or more vent holes. The vent holes may extend through afirst spacer layer, a second spacer, layer, or both. The vent holes mayextend from a rear surface to a forward surface so that the vent holesassist in directing fluid to a predetermined location. The vent holesmay align with each other, vent holes in the cover layer, or both. Afirst spacer layer material may be stiffer than a second layer of spacerlayer material. A first layer may extend under a second layer and thesecond layer may be softer than the first layer so that the second layerprevents an occupant from feeling components within the vehicle seat. Afirst spacer layer may be more pliable than a second spacer layer. Thefirst spacer layer and the second spacer layer may have the samepermeability. The spacer layer may have an air permeability of about7000 L/dm²/min; about 6000 L/dm²/min; or about 5000 L/dm²/min. The firstspacer layer may have a permeability of about 5000 L/dm²/min or less andthe second spacer layer may have a permeability of about 3000 L/dm²/minor less. The spacer layer may have a permeability of about 500 L/dm²/minor more, 1000 L/dm²/min or more, or about 1500 L/dm²/min or more. Thesecond spacer layer may extend over the first spacer layer. The secondspacer layer may be less rigid, have less read through, be morecompliable, or a combination thereof. The second spacer layer mayprovide comfort to an occupant, prevent an occupant from feeling a firstspacer layer, or both. The spacer layer may be a reticulated spacer, asoft spacer, or both. A permeability of a first spacer to a permeabilityof a second spacer may have a ratio of about 1:1 or more, about 1.2:1 ormore, about 1.5:1 or more, about 1.75:1 or more, about 2:1 or more, orabout 4:1 or less. The first spacer layer may be less permeable thanthen second spacer layer. The second spacer layer may be less permeablethan the first spacer layer. The first spacer layer may have less openspace than the second spacer layer. Voids or openings in the secondspacer layer may be larger than voids or openings in the first spacerlayer. A first spacer layer may have more voids or openings than thesecond spacer layer. The spacer layer may be an open cell foam. A secondspacer layer may have smaller pores than a first spacer layer and thesecond spacer layer may have more pores than the second spacer layer.The spacer layer may have a compression stress. The compression stressof the spacer layer may be about 5 kPa or more, about 7 kPa or more,about 10 kPa or more. The compression stress of the spacer layer may beabout 20 kPa or less or about 15 kPa or less. The compression stress ofthe spacer layer may vary by about ±2 or more, ±3 or more, or about ±4or more. The compressibility of the first spacer layer may be about 2kPa more than the second spacer layer. The compressibility of the firsspacer layer may be about 3 kPa more than the second spacer layer. Thecompressibility of the firs spacer layer may be about 4 kPa more thanthe second spacer layer. The first spacer layer may be thinner than thesecond spacer layer. The first spacer layer may be a same thickness asthe second spacer layer. The first spacer layer may be thicker than thesecond spacer layer. The first spacer layer, the second spacer layer, orboth may be a printed lattice structure. Preferably, the first spacerlayer is a lattice structure that creates open space that air may passthrough. Preferably, the spacer layer is a single layer of material thatis located between the cover layer and the rear layer.

The cover layer may function to distribute air flow to or frompredetermined locations. The cover layer may include one or more holesor vent holes. The cover layer may include a plurality of holes. The oneor more holes may be aligned with holes in a cushion, holes in a trimlayer, or both. The one or more holes may distribute air from the insertto locations that correspond with regions of an occupant (e.g., lowerback or legs). The one or more holes may be an absence of material. Theone or more holes may be formed by removing material. The one or moreholes may be formed by cutting the cover layer. The cover layer and therear layer may extend substantially parallel to each other withoutcontacting each other. The insert may be free of a cover layer, a rearlayer, or both. The spacer layer may be located between the cover layerand the rear layer but not connected to either the rear layer or thecover layer. The spacer layer may be connected to the rear layer, thecover layer, or both layers. The cover layer and the rear layer may beconnected together around edges to form a seam. The cover layer and rearlayer may be ultrasonically bonded together, melted together, gluedtogether, heat staked, or a combination thereof. The cover layer may beair permeable. The cover layer may be permeable. The cover layer may bemade of or include polyester, fleece, a woven material, a nonwovenmaterial, an extruded material, a film, or a combination thereof. Thecover layer and the rear layer may be connected together around edges,terminal locations, or both to form a seam (e.g., a peripheral edge).The cover layer may include one or more holes or vent holes.

The one or more vent holes may function to provide fluid to a locationof interest or remove fluid from a location of interest. The one or morevent holes may be an absence of material. The one or more vent holes maybe material that is cut, pressed, folded inward, or a combinationthereof. For example, the vent holes may be formed by cutting the coverlayer and folding the material inward. The one or more vent holes may belocated in a pattern to equally distribute air, to apply air to desiredlocations, or both. The insert may include a plurality of vent holes.The vent holes may extend through a spacer layer, a first spacer layer,a second spacer layer, a cover layer, or a combination thereof. A seammay seal one or more edges of the insert to direct air to the ventholes.

The one or more seams may function to create sealed edges so that aircan only leave the insert through predetermined locations. The one ormore seams may extend along each edge of the insert so that a completelysealed bag is formed. The seams may extend about an external edge of theinsert. The seams may extend around one or more connection holes alongone or more connection regions, or both. The one or more seams mayextend along only longitudinal edges or lateral edges. The one or moreseams may prevent fluid from exiting the insert. The one or more seamsmay join the cover layer, the rear layer, the trim layer, or acombination thereof together. The seams may be formed by sewing,adhesive, heating, melting, a mechanical fastener, a chemical fastener,glue, peel and stick layer, hot melt adhesive, or a combination thereof.The seams may be free of any of the insert layer. The seams may extendbeyond the insert layer so that the insert layer is entirely locatedbetween the top layer and the bottom layer. The seams may be located ina plane with the cover layer, the rear layer, or a locationtherebetween. Preferably, the one or more seams extend around aperiphery of the insert so that all edges of the insert substantiallyprevent air leakage. The one or more seams, the insert, or both mayinclude one or more connection holes. The one or more seams may extendalong one or more edged of the connection region.

The one or more connection regions function to connect to or moreregions of an insert potion, two or more parts of an insert, two insertportions, or a combination thereof. The one or more connection regionsmay be formed of a cover layer, a rear layer, a spacer layer, or acombination thereof. The one or more connection regions may be free of aspacer layer. The one or more connection regions may not transmit afluid. The one or more connection regions may have a fluid channel. Theone or more connection regions may be in contact with a connectiondevice. The one or more connection regions may be pulled down towardsthe cushion by a connection device so that the insert is retained inplace. The connection device may be formed by one or more cutouts inedges of the insert. The connection device may be two opposing cutoutsin opposing edges of the insert. The connection device may be formed bytwo connection holes.

The one or more connection holes may function to align an insert with acushion, to connect an insert to a cushion, or both. The one or moreconnection holes may form the connection region that connects the insertto the cushion, the connection member, or both. The one or moreconnection holes may extend through any portion of the insert. The oneor more connection holes may extend through a seam, extra material, anear along one or more edges of the insert, or a combination thereof.Preferably, the connection holes extend through a central portion of theinsert. The one or more connection holes may only be used to align thetrim bag with the cushion, holes in the cushion, a recess in thecushion, or a combination thereof. The one or more connection holes mayreceive a fastener, a portion of a connection device, or both. Twoopposing connection holes may corm a connection region that may be usedto connect the insert to the cushion. The connection holes may permit aconnection device of the trim layer to extend through the insert intocontact with a connection member of a cushion. The one or moreconnection holes may be free of connection and may be used for alignmentby temporarily being contacted during attachment. The insert may beadhesively connected to the cushion. For example, a two faced tape,liquid adhesive, adhesive film, or a combination thereof may connect theinsert to the cushion. The blower may assist in connecting the insert tothe cushion via one or more attachment rings. The insert may include oneor more attachment rings that allow air to be introduced into the insertwithout air escaping from the insert. The one or more connection holesmay permit a connection device to extend through the insert and connectto the cushion, the seat frame, or both.

The one or more connection devices may function to connect the insert,the trim layer, or both to the cushion, the connection member, or both.The connection devices may be part of the insert. The connection devicemay be directly connected to the insert. The connection device may beindirectly connected to the trim layer. The connection device may befree of a direct connection with the trim layer. The one or moreconnection devices may be a ring, a hog ring, a fastener, a clip, or acombination thereof. The one or more connection devices may extend fromthe trim layer, the insert, or both into contact with a connectionmember of the cushion so that the insert, the trim layer, or both ispulled down, connected to the cushion, prevented from moving, or acombination thereof. The connection device may be plastic, metal,self-closing, closed by a tool, or a combination thereof.

FIG. 1A is a perspective view of a conditioning system 2 connected to atrim layer 26. The conditioning system includes an insert 50 having aperipheral seam 52. The peripheral seam 52 connects the cover layer 54to the rear layer 56. The seam 52 in addition to connecting the coverlayer 54 and the rear layer 56 acts as a connection material 24 thatconnects the insert 50 to the trim layer 26. The cover layer 54 includesa plurality of through holes 62 that assist in directing fluid to alocation of interest.

FIG. 1B is a cross-sectional view of a conditioning system 2 connectedto a trim layer 26 and being cut along line 1B-1B in FIG. 1A. Theconditioning system 2 includes an insert 50 that is directly attached toa trim layer 26 via a connection material 24 so that the insert 50 andthe trim layer 26 form one unitary piece. The connection material 24also connects the cover layer 54 and the rear layer 56 together to formthe seam 52. The i seam 52/connection material 24 extend around aperipheral edge of the insert 50. The seam 52 encloses a heater 70 thatextends over two spacer layers 58, 58′. The two spacer layers 58, 58′have different material characteristics. The connection material formingthe seam 52, as shown, assists in connecting the insert 50 to the trimlayer 26. The spacer layer 58 may be a comfort layer that is morecompliant than the spacer layer 58′. The spacer layer 58 may be free ofread through the trim layer 26 so that an occupant (not shown) cannotfeel the heater 70, the spacer layer 58′, or both.

FIG. 1C is a cross-sectional view of a conditioning system 2 connectedto a trim layer 26 and being cut along line 10-10 in FIG. 1A. Theconditioning system 2 includes an insert 50 that is directly attached toa trim layer 26 via a connection material 24 so that the insert 50 andthe trim layer 26 form one unitary piece. The connection material 24also connects the cover layer 54 and the rear layer 56 together to formthe seam 52. The seam 52/connection material 24 extend around aperipheral edge of the insert 50. The seam 52 encloses a heater 70 thatextends over two spacer layers 58, 58′. The two spacer layers 58, 58′have different material characteristics. The spacer layer 58 and thecover layer 54 include through holes 62 and the spacer layer 58′ is freeof through holes. The connection material forming the seam 52, as shown,assists in connecting the insert 50 to the trim layer 26. The spacerlayer 58 may be a comfort layer that is more compliant than the spacerlayer 58′, however, the spacer layer 58 is less permeable than thenspacer layer 58′ and includes through holes 62 to direct airtherethrough. The spacer layer 58 may be free of read through the trimlayer 26 so that an occupant (not shown) cannot feel the heater 70, thespacer layer 58′, or both.

FIG. 2 is a cross-sectional view of a conditioning system 2 with aninsert 50 having a single spacer layer 58 located within the insert 50.The spacer layer 58 is retained within an insert 50 between a coverlayer 54 and a rear layer 56 that are connected together by a seam 52.The spacer layer 58 is maintained in communication with the trim layer26 by the connection material 24. A heater 70 is located within theinsert 50 between the cover layer 54 and the spacer layer 58.

FIG. 3 illustrates a cross-sectional view of a conditioning system 2.The conditioning system 2 is an insert 50 and blower 80 in fluidcommunication via a connection insert 86. The insert is directlyattached to a trim layer 26 via a connection material 24 so that theinsert 50 and the trim layer 26 form one unitary piece. The insert 50includes a cover layer 54 and a rear layer 56 that are connectedtogether forming a seam 52. The seam 52 encloses a heater 70 thatextends over a spacer layer 58. The insert 50 is located within a recess22 in the cushion 20 and connected to a connection insert 86 thatextends through a through hole 28 to connect a blower 80 to the insert50. The insert 50 is substantially a same size as the recess 22 in thecushion 20.

FIG. 3A illustrates a close-up of an opening 60 in an insert 50 of FIG.3. The insert 50 includes an opening 60 in the rear layer 56 that islarger than a channel 34 in the cushion 20 so that fluid freely entersthe insert 50.

FIG. 4A illustrates a cross-sectional view of a conditioning system 2integrated into a cushion 20. The cushion 20 includes a through hole 28that receives a blower 80. The blower 80 is connected to the cushion 20via a connection insert 86. The connection insert 86 provides air to thespacer 58 so that air moves through the spacer 58, cover layer 54,connection material 24, and through the trim layer 26 into communicationwith an occupant (not shown) at a surface of the trim layer 26. Theinsert 50 is free of a rear layer and the cover layer 54 forms a sealwith the cushion 20 so that air is directed through the spacer layer 58and holes in the trim layer 26. The connection material 24 connects thespacer layer 58 and heater 70 to the cover layer 54 and the cover layer54 is connected to the trim layer 26 by the connection material 24 sothat insert 50 is suspended from the trim layer 26. When an occupant(not shown) is in contact with the trim layer 26, the spacer layer 58 iscompressed over the connection insert 86 so that air is prevented frommoving between the spacer layer 58 and the cushion 20. The connectioninsert 86 mimics the stiffness of the foam so that the blower 80 ismovable with the cushion 20 as the cushion 20 moves with an occupant.

FIG. 4B illustrates a cross-sectional view of a conditioning system 2.The conditioning system 2 is an insert 50 that is directly attached to atrim layer 26 via a connection material 24 so that the insert 50 and thetrim layer 26 form one unitary piece. The insert 50 includes a coverlayer 54 and a rear layer 56 that extend along opposing surfaces of thespacer 58 but are free of contact with each other. The insert 50 is freeof a seam that encloses a heater 70 and spacer layer 58 within the coverlayer 54 and the rear layer 56. Each of the layers of the insert 50 areconnected together via the connection material 24. The connection layer24 is located between and connects the trim layer 26 to the cover layer54, the cover layer 54 to the spacer layer 58, and the spacer layer 58to the rear layer 56. The connection layer 24 assists in retaining theheater 70 between the spacer layer 58 and the cover layer 54. The insert50 is located with a recess in the cushion 20 and connected to aconnection insert 86 that extends through a through hole 28 to fluidlyconnect a blower 80 to the insert 50. A gap (G) is located between aside wall of the insert 50 and a side wall of the cushion 20 recess 22so that some fluid may pass between the insert 50 and the cushion 20.

FIG. 4C is a top view of an insert 50. The insert 50 includes a coverlayer 54 including a plurality of vent hole 62. The cover layer 54 isconnected to a trim layer (not shown) by connection material 24 thatextends along opposing edge regions.

FIG. 4D is a top view of an insert 50. The insert 50 includes a coverlayer 54 including a plurality of vent holes 62. The cover layer 54 isconnected to a trim layer (not shown by connection material 24. Theconnection material 54 covers regions of the cover layer 54 where airflow is not desired so that more air flow extends to desired regionssuch as the vent holes 62. As shown, the connection material 54 coversthe cover layer 54 so that an “X” shape is formed where no connectionmaterial 54 is present.

FIG. 5A illustrates a top view of an insert 50 having a first insertportion 50A and a second insert portion 50B. The first insert portion50A and the second insert portion 50B are connected together by aconnection region 40. The connection region 40 receives a connectiondevice 32 to assist in connecting the insert to a seat (not shown). Theinsert 50 includes a cover layer 54 and a rear layer 56 that areconnected together via a seam 52 that extends along all of the externaledges of the insert 50.

FIG. 5B is a top view of an insert 50 having a connection region 40. Theconnection region 40 is formed between two opposing connection holes 30.A connection device 32 extends around the connection region 40 andassists in connecting the insert 50 to a seat (not shown). A seam 52extends around an external periphery of the insert 50 and around each ofthe connection holes 30.

FIG. 5C illustrates a conditioning system 2 with an insert 50 thatincludes a connection hole 30. A connection device 32 extends throughthe connection hole 30 and connects the insert 50 to connection member36 in a cushion 20. The connection hole 30 divides the insert into twoinsert portions 50A and 50B. A blower 80 is connected to the cushion 20by a shield 84 that creates a pocket under the cushion 20 and covers thethrough holes 28. The shield 84 connects the blower 80 to the cushion 20and prevents air from exiting at a location other than through theinsert 50. The shield 84 directs air into the channels 34 in the cushion20 that are in fluid communication with the insert 50. The insert 50 isconnected to the trim layer 26 via a connection material 24 (e.g.,sewing or adhesive). The trim layer 26 may include a plurality of holesthat allow air to pass out through the insert 50 and the trim layer 26.The insert 50 includes a cover layer 54 and a rear layer 56 that areconnected together via seams 52. The insert 50 includes a heater 70 anda spacer 58.

FIG. 5D illustrates a cross-sectional view of part of a conditioningsystem 2 including a cushion 20 with a pair of through holes 28 formingchannels 34 in the cushion 20. A foam connection 88 connects a blower 80to the through holes 28 within the cushion 20. The foam connection 88directs air into each of the through holes 28 so that the air isdistributed to an occupant.

Any numerical values recited herein include all values from the lowervalue to the upper value in increments of one unit provided that thereis a separation of at least 2 units between any lower value and anyhigher value. As an example, if it is stated that the amount of acomponent or a value of a process variable such as, for example,temperature, pressure, time and the like is, for example, from 1 to 90,preferably from 20 to 80, more preferably from 30 to 70, it is intendedthat values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. areexpressly enumerated in this specification. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to be considered to beexpressly stated in this application in a similar manner.

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of” to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist essentially of orconsist of the elements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theteaching should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

2 Conditioning System

20 Cushion

22 recess

24 Connection material (sewn/adhesive)

26 Trim layer

28 Through hole

30 Connection holes

32 Connection device

50 Insert

52 Seam

54 Cover layer—most likely a fleece

56 Rear layer

58 Spacer layer

70 Heater—on underside of fleece—

80 Blower

84 Shield/plenum

86 Connection insert/compressible duct bellows

88 Foam connection/plenum

90 Trunk

92 branch

1) An insert for a climate controlled vehicle seat, the insertcomprising: a cover layer; a heater arranged below the cover layer; aconnection layer arranged below the heater; and a spacer layer locatedbelow the connection layer; wherein the vehicle seat comprises a cushionhaving a recess defined in a top side thereof, and at least a portion ofthe insert is configured to be received into the recess and then coveredby a trim layer of the vehicle seat. 2)-16) (canceled) 17) The insertaccording to claim 1, wherein the spacer layer comprises one or morevent holes. 18) The insert according to claim 17, wherein the connectionlayer is applied around the one or more vent holes in the spacer layer.19) The insert according to claim 18, wherein the heater is attacheddirectly to a top surface of the connection layer and the spacer layeris attached directly to a bottom surface of the connection layer. 20)The insert according to claim 19, wherein the heater is attacheddirectly to a bottom side of the cover layer, and an opposing top sideof the cover layer is attached directly to the trim layer of the vehicleseat. 21) The insert according to claim 20, wherein the spacer layer isattached directly to the cushion. 22) The insert according to claim 21,wherein the insert is free of any layers between the spacer layer andthe cushion. 23) The insert according to claim 18, wherein theconnection layer comprises tape. 24) The insert according to claim 23,wherein the tape is air permeable. 25) The insert according to claim 24,wherein the connection material comprises one or more strips. 26) Theinsert according to claim 1, wherein the spacer layer comprisesreticulated foam. 27) The insert according to claim 26, wherein theheater is attached directly to a top surface of the connection layer andthe spacer layer is attached directly to a bottom surface of theconnection layer. 28) The insert according to claim 27, wherein thespacer layer is attached directly to the cushion without any layersbetween the spacer layer and the cushion. 29) The insert according toclaim 1, wherein when the insert is viewed in cross section, the coverlayer has a width that is wider than a width of the spacer layer. 30)The insert according to claim 29, wherein a top surface of the coverlayer is generally aligned with a top surface of the cushion after theinsert is received into the recess. 31) The insert according to claim29, wherein the cushion comprises a second recess surrounding therecess, the cover layer is supported in the second recess and the spacerlayer is received into the recess. 32) The insert according to claim 31,wherein the second recess has a ledge upon which the cover layer issupported, the ledge is generally parallel to a bottom surface of therecess upon which the spacer layer is supported. 33) The insertaccording to claim 1, wherein when the insert is viewed in crosssection, a width of the recess is greater than a width of the spacerlayer so that a gap is defined between a side wall of the spacer layerand a side wall of the recess. 34) The insert according to claim 1,wherein the insert is connected to the blower via a connection insert,that extends at least partially through a thickness of the cushion andwhen an occupant is in contact with the trim layer, the spacer layer iscompressed over the connection insert so the air is prevented frommoving between the spacer layer and the cushion. 35) The insertaccording to claim 34, wherein the cushion comprises a through hole intowhich the blower is received.